U.S. patent application number 16/301964 was filed with the patent office on 2019-08-22 for skirt for forming an access hatch in concrete.
The applicant listed for this patent is EJ USA, Inc.. Invention is credited to Timothy J. McKernan.
Application Number | 20190257055 16/301964 |
Document ID | / |
Family ID | 60411854 |
Filed Date | 2019-08-22 |
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United States Patent
Application |
20190257055 |
Kind Code |
A1 |
McKernan; Timothy J. |
August 22, 2019 |
SKIRT FOR FORMING AN ACCESS HATCH IN CONCRETE
Abstract
A skirt supports an access hatch at a predetermined height as
the hatch is formed in concrete. The skirt can be permanently
embedded in the concrete. The skirt includes a rigid frame defining
a central opening, the frame has an inner surface and an outer
surface opposite the inner surface. The frame defines a height
between the upper edge and the lower edge. The height of the skirt
is predetermined such that the combined height of the skirt and the
hatch approximate the desired thickness of the concrete slab. The
skirt may include an alignment tab extending from the frame at an
angle with respect to the frame, with the alignment tab extending
above the upper edge of the frame to guide the hatch into alignment
with the upper edge of the frame as the hatch is moved into
position on the skirt.
Inventors: |
McKernan; Timothy J.;
(Baldwinsville, NY) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
EJ USA, Inc. |
East Jordan |
MI |
US |
|
|
Family ID: |
60411854 |
Appl. No.: |
16/301964 |
Filed: |
May 27, 2016 |
PCT Filed: |
May 27, 2016 |
PCT NO: |
PCT/US2016/034529 |
371 Date: |
November 15, 2018 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E02D 2250/0007 20130101;
E02D 29/14 20130101; E02D 2300/002 20130101; E02D 2250/0023
20130101 |
International
Class: |
E02D 29/14 20060101
E02D029/14 |
Claims
1. A skirt for supporting a hatch formed in concrete, the skirt
comprising: a rigid frame including a sidewall defining a central
opening, the sidewall having an inner surface facing the central
opening, an outer surface opposite the inner surface, an upper edge
and a lower edge opposite the upper edge, the sidewall defining a
height between the upper edge and the lower edge; and an alignment
tab extending from the sidewall at an angle with respect to the
sidewall, at least a portion of the alignment tab extending beyond
and above the upper edge of the sidewall such that the alignment
tab guides the hatch into alignment with the upper edge of the
sidewall as the hatch is moved into position on the upper edge of
the sidewall.
2. The skirt of claim 1 wherein the alignment tab includes an inner
plate extending from the inner surface of the sidewall and an outer
plate extending from the outer surface of the sidewall.
3. The skirt of claim 2 wherein the inner plate extends at an angle
from the inner surface and the outer plate extends at an angle from
the outer surface, the inner and outer plates together forming a
V-shape that converges toward the upper edge of the sidewall.
4. The skirt of claim 1 including at least one retention tab
extending outwardly from the outer surface of the sidewall and
spaced apart from the alignment tab.
5. The skirt of claim 1 including a flange extending outwardly from
the outer surface of the sidewall and spaced from the alignment tab
and the retention tab, the flange positioned on the sidewall such
that it aligns underneath an opening in the hatch and closes the
opening to prevent the flow of concrete into the opening when the
hatch is seated on the skirt.
6. A method for forming a hatch into precast concrete, comprising:
providing a concrete form; placing a rigid skirt frame into the
concrete form, the frame including a sidewall defining a central
skirt opening, the sidewall having an inner surface facing the
central opening, an outer surface opposite the inner surface, an
upper edge and a lower edge opposite the upper edge, the sidewall
defining a height between the upper edge and the lower edge;
placing a hatch onto the skirt frame, the hatch having a frame
defining a central hatch opening, the hatch frame including an
inner surface facing the central hatch opening, an outer surface,
an upper edge and a bottom edge defining a hatch height, the bottom
edge of the hatch seated on the top edge of the skirt frame, the
central hatch opening aligned with the central skirt opening, the
hatch having a cover for covering the central hatch opening; and
pouring concrete into the concrete form around the outer surface of
the skirt and the outer surface of the hatch.
7. The method of claim 6 including filling the concrete form with
concrete to a level generally equal to the combined height of the
skirt frame and the hatch frame.
8. The method of claim 7 including providing at least one alignment
tab extending from the skirt frame beyond the upper edge of the
skirt frame, wherein the step of placing the skirt frame on the
hatch frame includes guiding the bottom edge of the hatch frame
onto the upper edge of the skirt frame with the alignment tab.
9. The method of claim 8 wherein the at least one alignment tab
includes a pair of plates arranged in a V-shape that converges
towards the upper edge of the skirt frame.
10. The method of claim 9 wherein the skirt frame includes at least
one retention tab extending outwardly from the outer surface of the
skirt frame, and wherein the concrete is poured around the at least
one retention tab, the retention tab having a hook shape.
11. The method of claim 10 wherein the hatch includes a hinge for
connecting the cover to the hatch frame, the hinge disposed in a
cutout in the hatch frame, the cutout having an open bottom, and
wherein the skirt frame includes at least one flange extending
outwardly therefrom and spaced from the retention tab and the
alignment tab, the hatch frame placed on the skirt with the at
least one flange closing the open bottom of the cutout, preventing
the flow of concrete into the cutout as the concrete is poured into
the form.
12. The method of claim 11 wherein the flange is flush with the
upper edge of the skirt.
13. A system for forming a hatch into concrete, comprising: a rigid
skirt frame including a sidewall defining a central skirt opening,
the sidewall having an inner surface facing the central opening, an
outer surface opposite the inner surface, an upper edge and a lower
edge opposite the upper edge, the sidewall defining a height
between the upper edge and the lower edge; and a hatch seated on
the skirt frame, the hatch having a frame defining a central hatch
opening, the hatch frame including an inner surface facing the
central hatch opening, an outer surface, an upper edge and a bottom
edge defining a hatch height therebetween, the bottom edge of the
hatch seated on at least a portion of the top edge of the skirt
frame, the central hatch opening aligned with the central skirt
opening; a cover for covering the central hatch opening, and a
hinge for connecting the cover to the hatch frame, the hinge
disposed in a cutout in the hatch frame, the cutout having an open
bottom, wherein the skirt frame includes at least one flange
extending outwardly therefrom, the hatch frame placed on the skirt
with the at least one flange closing the open bottom of the
cutout.
14. The system of claim 13 including an alignment tab extending
from the skirt frame at an angle with respect to the sidewall, at
least a portion of the alignment tab extending beyond and above the
upper edge of the skirt frame such that the alignment tab can guide
the hatch into alignment with the upper edge of the skirt frame as
the hatch is moved into position on the upper edge of the sidewall
of the skirt frame.
15. The system of claim 14 wherein the alignment tab includes an
inner plate extending from the inner surface of the skirt frame and
an outer plate extending from the outer surface of the skirt
frame.
16. The system of claim 15 wherein the inner plate extends at an
angle from the inner surface and the outer plate extends at an
angle from the outer surface, the inner and outer plates together
forming a V-shape that converges toward the upper edge of the skirt
frame.
17. The system of claim 16 including at least one retention tab
extending outwardly from the outer surface of the skirt frame and
spaced apart from the alignment tab.
18. The system of claim 17 wherein the retention tab has a hook
shape.
19. The system of claim 18 wherein the flange extending outwardly
from the skirt frame is and spaced from the alignment tab and the
retention tab.
20. The system of claim 19 wherein the flange is flush with the
upper edge of the skirt frame.
Description
BACKGROUND OF THE INVENTION
[0001] The present invention is directed to the forming of items
into a slab of precast concrete, and, more specifically, to the
forming of an access hatch into a slab of precast concrete.
[0002] Precast, or preformed concrete is well known. In general, a
form is made in the desired shape of the concrete, and then
concrete is poured into the form and let to cure in the shape of
the form. After the concrete has cured, the form can be removed and
the slab of concrete can be transported for use in a final
application. In many cases, there is a desire to insert one or more
structural elements into the slab of concrete. For example, if the
slab of concrete is to be placed over an opening, there is often a
desire to include an access hatch in the slab of concrete to
provide access to the opening after the slab of concrete has been
placed.
[0003] Access hatches are also well known. These hatches generally
include a rigid outer frame, often cast iron, that defines a
central access opening. A cover attaches to the frame for covering
the access opening. The cover can be opened to provide access to
the opening, for example, by pivoting the cover on one or more
hinges formed into the frame. In situations where a hatch is to be
inserted into a concrete slab, the hatch is transported and lowered
into the concrete form prior to the pouring of concrete, and then
the concrete is poured into the form around the outer frame. When
the concrete has cured, the hatch is embedded in the concrete slab
and can be transported with the slab to the final application for
insertion over an opening.
[0004] Problems can arise when forming a hatch into concrete,
because hatches generally have a standard height of about five
inches. In many cases, the desired height of the concrete is
greater than five inches, such as eight, ten or twelve inches. In
order to position the hatch in the form at the desired height of
the surface of the concrete, a special form is typically made. The
form is generally made from wood or Styrofoam with a height that
can raise the hatch to the desired level of the concrete, such that
the form is placed in the concrete form, and then the hatch is
lowered onto the form. After the concrete has been poured and
cured, the hatch must be opened and then the wood or Styrofoam form
must be removed from the lower surface of the slab to provide
access to the hatch opening. This process of creating, inserting
and removing a special temporary form for raising the hatch to a
desired height is both time consuming and laborious.
SUMMARY OF THE INVENTION
[0005] The present invention provides a skirt that supports a hatch
at a predetermined height as the hatch is formed within a slab of
concrete. The skirt can be embedded and retained in the concrete.
The skirt may include features for assisting in the placement of
the hatch and the formation of the concrete.
[0006] In one embodiment, the skirt includes a rigid frame
including a sidewall defining a central opening, the sidewall has
an inner surface facing the central opening, an outer surface
opposite the inner surface, an upper edge and a lower edge opposite
the upper edge, the sidewall defines a height between the upper
edge and the lower edge. The height of the skirt is predetermined
such that the combined height of the skirt and the hatch
approximate the desired thickness of the concrete slab.
[0007] The skirt may include an alignment tab extending from the
sidewall at an angle with respect to the sidewall, at least a
portion of the alignment tab extending beyond and above the upper
edge of the sidewall such that the alignment tab guides the hatch
into alignment with the upper edge of the sidewall as the hatch is
moved into position on the upper edge of the sidewall. In one
embodiment, the alignment tab includes an inner plate extending
from the inner surface of the sidewall and an outer plate extending
from the outer surface of the sidewall. In another embodiment, the
inner plate extends at an angle from the inner surface and the
outer plate extends at an angle from the outer surface, the inner
and outer plates together forming a V-shape that converges toward
the upper edge of the sidewall.
[0008] In another embodiment, the skirt includes at least one
retention tab extending outwardly from the outer surface of the
sidewall and spaced apart from the alignment tab. The retention tab
may have a hook shape to assist in retaining the skirt within the
concrete when the concrete has been poured and cured.
[0009] In another embodiment, the skirt includes a flange extending
outwardly from the outer surface of the sidewall and spaced from
the alignment tab and the retention tab, the flange is positioned
on the sidewall such that it aligns underneath an opening in the
hatch and closes the opening to prevent the flow of concrete into
the opening when the hatch is seated on the skirt.
[0010] The present invention also provides a method for forming a
hatch into precast concrete, comprising: providing a concrete form;
placing a rigid skirt frame into the concrete form, the frame
including a sidewall defining a central skirt opening, the sidewall
having an inner surface facing the central opening, an outer
surface opposite the inner surface, an upper edge and a lower edge
opposite the upper edge, the sidewall defining a height between the
upper edge and the lower edge; placing a hatch onto the skirt
frame, the hatch having a frame defining a central hatch opening,
the hatch frame including an inner surface facing the central hatch
opening, an outer surface, an upper edge and a bottom edge defining
a hatch height, the bottom edge of the hatch seated on the top edge
of the skirt frame, the central hatch opening aligned with the
central skirt opening, the hatch having a cover for covering the
central hatch opening; and pouring concrete into the concrete form
around the outer surface of the skirt and the outer surface of the
hatch.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is top perspective view of a skirt according to one
embodiment of the present invention.
[0012] FIG. 2 is a bottom perspective view thereof.
[0013] FIG. 3 is a top perspective view of a hatch frame and
skirt.
[0014] FIG. 4 is a bottom perspective view of a hatch frame and
skirt.
[0015] FIG. 5 is a view of a concrete form.
[0016] FIG. 6 is a view of a skirt positioned within the form.
[0017] FIG. 7 is a view of a hatch prepared to be transported to
the form.
[0018] FIG. 8 is a view of the hatch being transported to the
form.
[0019] FIG. 9 is a view of the hatch being lowered into position
above the skirt and form.
[0020] FIG. 10 is a view of the concrete being poured into the form
with the hatch positioned on the skirt.
[0021] FIG. 11 is a view of the concrete poured into the form.
[0022] FIG. 12 is a close up view of the concrete poured about the
hatch.
DETAILED DESCRIPTION OF THE CURRENT EMBODIMENTS
I. Overview
[0023] A skirt for forming an access hatch in precast concrete is
shown in FIG. 1 and generally designated 10. The skirt 10 is a
generally rigid open frame having an upper edge 12 and a lower edge
14 defining a height 16 therebetween. The height 16 may be
predetermined to correspond to a desired height of a preformed slab
of concrete 18 into which the hatch 20 is to be formed, such that
the combined height of the skirt 10 and the hatch 20 matches the
height of the concrete. The skirt 10 includes features for aligning
the hatch 20 on the skirt 10, and for preventing the flow of
concrete into certain areas of the hatch 20, and also for
preventing the removal of the skirt 10 from the concrete 18.
II. Structure
[0024] As shown in FIGS. 1 and 2, the skirt 10 is a frame having a
sidewall 11 defining a central opening 22 for aligning with an
opening in the hatch 20. The frame is formed from a rigid material,
such as aluminum, that can maintain its shape when supporting the
weight of a cast iron hatch 20. In one embodiment, the skirt 10
includes an upper edge 12 and a lower edge 14 defining a height 16
therebetween. An inner surface 24 faces the central opening 22, and
an outer surface 26 faces away from the central opening 22. In the
illustrated embodiment, the skirt 10 is rectangular in shape, but
it should be known that the shape can change from application to
application.
[0025] The skirt 10 is designed to support a generally conventional
hatch 20 in a precast concrete form 30 (described in more detail
below). For example, the hatch 20 may be seated on the upper edge
12 of the skirt 10 when in the form 30 to raise the height of the
hatch 20 to be generally flush with the surface of the concrete 18.
Referring to FIGS. 3 and 4, the hatch 20 also includes a sidewall
32 defining a central opening 34. The sidewall 11 of the skirt 10
is designed to match the size and shape of the sidewall 32 of the
hatch 20 such that the hatch 20 can be placed on the skirt 10 with
the respective sidewalls 11, 32 being generally flush with one
another or at least with portions of sidewall 11 of the skirt 10
being sufficiently aligned with the sidewalls 32 of the hatch 20 to
support the weight of the hatch 20 when the hatch 20 is placed on
the skirt 10. As further illustrated in FIGS. 3 and 4, the hatch 20
may include a bottom edge 36 and a top edge 38 opposite the bottom
edge 36. In the illustrated embodiment, a flange 40 extends
outwardly from the top edge 38 in a direction perpendicular to the
sidewall 32 forming an upper surface of the hatch 20.
[0026] As shown in FIGS. 7-12, the hatch 20 also includes a cover
42 that can be closed to extend over and cover the central opening
34 of the hatch 20 and opened to provide access to the central
opening 34. In one embodiment, the cover 42 attaches to the
sidewall 32 (or another portion of the hatch 20) with one or more
hinges 44. As shown, the hinges 44 are formed within U-shaped
cutouts 46 in the flange 40, and in one embodiment these cutouts 46
include an open bottom 48 that is exposed to the environment.
Although the cover 42 is shown in a closed position in FIGS. 7-12,
it should be known that the cover 42 can be pivoted about the
hinges 44 from this closed position to an open position about a
pivot axis that extends through the hinges 44.
[0027] The skirt 10 may include one or more structural features
that assist in the process of forming a slab of concrete 18 around
the stacked hatch 20 and skirt 10. In one example, shown in FIGS.
1-4 and 6, the skirt includes one or more alignment tabs 50
extending from the sidewall 11 of the skirt 10. These alignment
tabs 50 function to guide the hatch 20 into alignment with the
skirt 10 as the hatch 20 is lowered onto the skirt 10. In one
embodiment, each alignment tab 50 includes a pair of plates 52, 54,
with a first plate 52 extending from the inner surface 24 and a
second plate 54 extending from the outer surface 26. The plates 52,
54 extend at an angle from the skirt 10 and beyond the upper edge
12 of the skirt to form a V-shape that converges towards the upper
edge 12 of the skirt 10, wherein each plate 52, 54 acts as a ramp
to guide the hatch 10 into alignment on the upper edge 12 of the
skirt 10. In the illustrated embodiment, the plates 52, 54 of each
alignment tab 50 are positioned directly across from one another,
and a series of alignment tabs 50 are spaced apart about the
sidewall 11. In another embodiment, each alignment tab 50 may
include only a single one of the plates 52 or 54. For example, a
plate 52 on the inner surface 24 of the skirt 10 may be spaced
along the sidewall 11 from a plate 54 on the outer side 26 of the
sidewall 11.
[0028] In one embodiment, the skirt 10 may include one or more
flanges 60 extending outwardly to align with one or more regions of
the hatch 20 to prevent the unwanted flow of concrete into those
regions. Referring to FIGS. 2 and 4, in the illustrated embodiment
the skirt 10 includes a pair of flanges 60 that are positioned on
the sidewall 11 of the skirt 10 such that they each align
underneath an open bottom 48 of one of the U-shaped hinge cutouts
46 to close off the open bottom 48 when the hatch 20 is seated on
the skirt 10 and prevent the flow of concrete 18 into the hinge
cutout 46. The flanges 60 thus keep the U-shaped cutouts 46 clear
of concrete as the concrete is poured to enable full operation of
the hinges after the concrete 18 sets. In this embodiment, the
flanges 60 are L-shaped, including a first generally vertical leg
62 abutting flat against the sidewall 11 of the skirt and a section
generally horizontal leg 64 extending at about a 90 degree angle
from the first leg 62 in a direction away from the sidewall 11. The
horizontal leg 64 is flush with the upper edge 12 of the skirt such
that the open bottom 48 of the hinge cutouts 46 abuts the
horizontal leg 64 of the flange 60. In another embodiment, other
shapes and sizes of flanges may be positioned on the skirt 10 to
align with other structures on the hatch 10 in order to prevent the
unwanted flow of concrete into such structures.
[0029] Referring again to FIGS. 1-4, and also FIG. 6, the skirt 10
may include structural features to prevent the movement or removal
of the skirt 10 from the concrete 18 after the concrete 18 has
cured. As illustrated, the skirt 10 includes retention flanges 70
extending outwardly from the outer surface 26 of the skirt 10. The
retention flanges 70 are spaced apart along each side of the
sidewall 11, with either three retention flanges 70 or two
retention flanges 70 per side. Each retention flange includes a
first portion 72 connected to the sidewall 11 and positioned flat
against the sidewall 11, a second portion 74 extending outwardly at
an angle from the first portion 72, and a third portion 76
extending at an angle from the second portion 74 and in a generally
upward direction, such that each retention flange 70 has a hook
shape. The retention flanges 70 are spaced apart from the alignment
tabs 50 and the flanges 60. In an alternative embodiment, the
retention flanges 70 may be differently shaped, sized or
spaced.
[0030] FIGS. 10-12 show examples of the hatch 20 with skirt 20
formed into a concrete slab 18. As shown, the height 16 of the
skirt 10 is such that the lower edge 14 of the skirt 10 is
positioned on the bottom of the concrete form 30, and thus at the
bottom of the concrete slab 18, while the top flange 40 of the
hatch 20 being generally flush with the top of the concrete form
and thus the top of the concrete slab 18.
III. Manufacture
[0031] Manufacture of a precast slab of concrete 18 with embedded
hatch 20 and skirt 10 is shown in FIGS. 5-12.
[0032] FIG. 5 shows a conventional concrete form 30. The form 30 is
circular, and is lined with rebar 108. FIG. 6 shows a skirt 10
positioned in the concrete form 30.
[0033] FIG. 7 shows a generally conventional hatch 20 positioned on
a shelf 102 with lift chains 104 connected to the hatch 20 for
movement of the hatch 20. The hatch cover 42 is in a closed
position, and the sidewall 32 of the hatch 20 is oriented
vertically with the bottom edge 36 seated on the shelf 102.
[0034] FIG. 8 shows the hatch 20 being transported into position
above the concrete form 30. The form 30 is circular, and is lined
with rebar 108. The skirt 10 is positioned in the form 30 at the
bottom 110 of the form 30 with the alignment tabs 50 extending
upwardly.
[0035] FIG. 9 shows the hatch 20 being lowered onto the skirt 10,
with the bottom edge 36 of the hatch 20 generally aligned above the
upper edge 12 of the skirt 10. As the hatch 20 continues to be
lowered, the sidewall 32 of the hatch 20 extends between the plates
52, 54 of the alignment tabs 50 and is guided into alignment with
the sidewall 11 of the skirt 10 with each wall of the sidewall 11
of the hatch 10 being aligned underneath a corresponding wall of
the sidewall 32 of the hatch 20.
[0036] FIG. 10 shows the hatch 20 in position on top of the skirt
10, with the bottom edge 36 of the hatch 20 seated on the upper
edge 12 of the skirt (similar to the arrangement shown in FIGS. 3
and 4). Weights 112 are placed on top of the hatch 20 to hold the
hatch 20 in place. Concrete 18 is dispensed into the form 30. As
the concrete 18 is dispensed into the form 30, the flanges 60
prevent the flow of concrete 18 into the hinge cutouts 46 and the
retention flanges 70 project outwardly into the flow of concrete
such that the concrete 18 flows around the hook shaped retention
flanges 60 to prevent the removal of the skirt 10 from the concrete
18 after the concrete 18 has cured.
[0037] FIGS. 11 and 12 show the concrete form 30 filled with
concrete 18 such that the concrete 18 is generally level with the
top edge 38 and flange 40 of the hatch 20. Once cured, the concrete
18 can be removed from the form 30 with the hatch 20 and skirt 10.
The skirt 10 remains generally embedded in the concrete 18 and does
not need to be removed from the concrete 18.
[0038] The above description is that of the current embodiment of
the invention. Various alterations and changes can be made without
departing from the spirit and broader aspects of the invention as
defined in the appended claims, which are to be interpreted in
accordance with the principles of patent law including the doctrine
of equivalents. Any reference to claim elements in the singular,
for example, using the articles "a," "an," "the" or "said," is not
to be construed as limiting the element to the singular.
* * * * *